Sanyo DC-MCR80M Assembly instructions

Service Manual
FILE NO.
REFERENCE No. SM5810775
PRODUCT CODE No.
129 703 04
Micro Component System DC-MCR80M (AU)
CONTENTS
Laser Beam Safety Precaution ........................................ 1
Tuner Adjustment ............................................................. 2
Exploded View (Accessories & Packing) ......................... 3
Exploded View (Cabinet & Chassis) ................................ 4
Parts List .......................................................................... 6
Wiring Connection ............................................................ 9
Schematic Diagram .......................................................... 10
Wiring Diagram ................................................................ 14

- 1 -
• Pickup that emits a laser beam is used on this CD section.
CAUTION :
USE OF CONTROLS OR ADJUSTMENTS OR
PERFORMANCE OF PROCEDURES OTHER
THAN THOSE SPECIFIED HEREIN MAY RESULT
IN HAZARDOUS RADIATION EXPOSURE.
LASER OUTPUT................ 0.6 mW Max. (CW)
WAVE LENGTH ................. 790 nm
LASER BEAM SAFETY PRECAUTION
CAUTION – INVISIBLE LASER RADIATION WHEN OPEN AND
INTERLOCKS DEFEATED. AVOID EXPOSURE TO BEAM.
ADVARSEL – USYNLIG LASER STRÅLING VED ÅBNING, NÅR
SIKKERHEDSAFBRYDERE ER UDE AF FUNKTION, UNDGÅ UDS ÆTTELSE
FOR STRÅLING.
VARNING – OSYNLIG LASER STRÅLNING NÄR DENNA DEL ÄR ÖPPNAD
OCH SPÄRR ÄR URKOPPLAD. STRÅLEN ÄR FARLIG.
VORSICHT – UNSICHTBARE LASERSTRAHLUNG TRITT AUS, WENN
DECKEL GEÖFFNET UND WENN SICHERHEITSVERRIEGELUNG
ÜBERBRÜCKT IST. NICHT, DEM STRAHL AUSSETZEN.
VARO – AVATTAESSA JA SUOJALUKITUS OHITETTAESSA OLET ALTTIINA
NÄKYMÄTTÖMÄLLE LASERSÄTEILYLLE. ÄLÄ KATSO SÄTEESEEN.
CLASS 1 LASER PRODUCT
LUOKAN 1 LASERLAITE
KLASS 1 LASERAPPARAT

- 2 -
TUNER ADJUSTMENTS
Use a plastic screw driver for adjustments.
Adjust the intermediate frequency of AM to the frequency of ceramic filter.
Set of unit
Supply voltage :AC 220V
speaker impedance :4 ohms
standard output :500 mW
Function select: :TUNER
a. Parts Location
a.AM Adjustment Band :AM
SG Position of VTVM
Input Output Frequency Tuning dial Oscilloscope
Closed the output
termial by sweep
generator,it place
to AM ANT
Connect AM SG to Connect VTVM to 522 KHz 522 KHz T103 VT: 1.2V
test loop R103 1611 KHz 1611 KHz VT: 7.5V or so
Connect AM SG to Connect VTVM to 603 KHz 603 KHz T101
test loop speaker terminals. 1404 KHz 1404KHz TC101
b.FM Adjustment Band :FM FM Dummy antenna: 75 ohms unbalance
SG Position of VTVM
Input Output Frequency Tuning dial Oscilloscope
Connect FM SG to Connect VTVM to 87.50 MHz 87.50 MHz L103 VT: 2.0V
D102(+) & D104(-) R104 108.00 MHz 108.00 MHz VT: 7.0V or so
Connect FM SG to Connect VTVM to 90.00 MHz 90.00 MHz L102
D102(+) & D104(-) speaker terminals. 106.00 MHz 106.00 MHz TC102
Tracking Max.
Connect VTVM to
C110(-)
90.00 MHz
Tuning
cover range
IF
Connect sweep
generator to
C101
Connect VTVM to
C110(-) 10.7 MHz
Adjusting Connection
Max.
Adjustment
Circuit
Tracking
Adjustment
IF T102
Tuning
522 KHz450 KHz
Connections
cover range
Adjusting
Circuit
2
1
Step
3
2
3
Step
1

- 3 -
EXPLODED VIEW(ACCESSORIES & PACKING)

- 5 -- 4 -
EXPLODED VIEW(CABINET & CHASSIS)
45A
*
*
46A
S3
S2
S4
24
S12
23
21
22
S13
20
S10
S10
S11
S6
S5
S3
S1
S2
S8
S9
S7
15
9
10
76
34
32
14
13
12
74
25 7
1
2
3
4
5
18
19
16
75
75
8
31
28
S14
35
33
S15
40
*
70
71
72
73
*
*
*
*
**
*
*
*
*
*
*
*
*
*
*
*
*
**
36A
*
*
*
6A
*
*
*
*
*
*
*
*
: Not available as service parts.
*
*
*
*

- 6 -
PARTS LIST
CAUTION : Regular type resistors and capacitors are not listed. To know those values, refer to the schematic diagram.
Regular type resistors are less than 1/4W carbon type and 0 ohm chip resistors.
Regular type capacitors are less than 50V and less than 1000µF of Ceramic type and Electrolytic type.
PRODUCT SAFETY NOTICE
EACH PRECAUTION IN THIS MANUAL SHOULD BE FOLLOWED DURING SERVICING. COMPONENTS IDENTIFIED WITH
THE IEC SYMBOL !
!! IN THE PARTS LIST AND THE SCHEMATIC DIAGRAM DESIGNATE COMPONENTS IN WHICH SAFETY
CAN OF SPECIAL SIGNIFICANCE. WHEN REPLACING A COMPONENT IDENTIFIED , USE ONLY THE REPLACEMENT
PARTS DESIGNATED, OR PARTS WITH THE SAME RATINGS OF RESISTANCE, WATTAGE OR VOLTAGE THAT ARE
DESIGNATED IN THE PARTS LIST IN THIS MANUAL. LEAKAGE-CURRENT OR RESISTANCE MEASUREMENTS MUST
BE MADE TO DETERMINE THAT EXPOSED PARTS ARE ACCEPTABLY INSULATED FROM THE SUPPLY CIRCUIT
BEFORE RETURNING THE PRODUCT TO THE CUSTOMER.
PACKING & ACCESSORIES
REF.NO. PART NO. DESCRIPTION
1 645 070 9296 POLY BAG,AM LOOP ANT
2645 061 6297 ANTENNA LOOP
3645 062 2014 POLY BAG,UNIT
4645 081 8073 REMOTE CONTROL,
RC30-X000S3-021
5645 076 1898 POLY FOAM,KIT
6645 084 2085 GIFT BOX
645 081 5270 INSTRUCTION MANUAL
645 027 2073 POLY BAG,AC CORD
645 066 6063 POLY BAG,I/B
645 062 2007 POLY BAG,SPEAKER
!
!! 645 084 2078 POWER CORD,SAA
645 080 5370 WIRE JOIN UL/CSA APPROVAL,
AC CORD TO PWR TRAN
CABINET & CHASSIS
REF.NO. PART NO. DESCRIPTION
1645 076 2062 CD DOOR
2645 076 1829 LEFT LED LENS COVER
3645 076 1805 LEFT LED BACKLIGHT LENS
4 645 076 1836 RIGHT LED LENS COVER
5 645 076 1812 RIGHT LED BACKLIGHT LENS
6A 645 076 2154 ASSY CABINET TOP
7645 076 1560 KNOB VOLUME
8645 076 1577 VOLUME KNOB BRACKET
9 645 076 1461 CD DECK MECHANISM
10 645 033 3446 RUBBER SILICON,CD DECK
13 645 076 1980 CABINET BOTTOM
14 645 076 1997 BOTTOM CAB COVER
15 645 076 2048 PANEL SIDE LEFT
16 645 076 2055 PANEL SIDE RIGHT
19 645 076 2086 CABINET BACK COVER
21 645 076 1539 PULLEY WORM GEAR
22 645 076 1850 CD DOOR GEAR
23 645 076 1522 MOTOR PULLEY
24 645 062 1420 MOTOR BKT
25 645 076 1546 SCREW CLIP
28 645 076 1713 LED BRACKET
31 645 076 1683 REMOTE RECEIVER BRACKET
32 645 076 1782 DISPLAY BACKLIGHT LENS
33 645 076 1706 DISPLAY BRACKET
34 645 076 1676 DISPLAY BRACKET PLATE,LEFT
35 645 076 1676 DISPLAY BRACKET PLATE,RIGHT
40 645 076 1843 LINE CORD HOLDLE
36A 645 076 2147 ASSY CABINET FRONT
45A 645 081 8080 ASSY SPEAKER BOX L,LEFT
46A 645 081 8097 ASSY SPEAKER BOX R,RIGHT
FIXING PARTS
REF.NO. PART NO. DESCRIPTION
S1 645 023 6594 SCREW ST 3X8,CONTROL BD
S2 645 069 6770 SCREW 2.6X8,CD DECK
S3 645 023 6594 SCREW ST 3X8,MAIN BD
S4 645 023 6594 SCREW ST 3X8,DISPLAY BRACKET
S5 645 076 1140 SCREW 3X20,PWR TRANS
S6 645 027 3841 SCR 3X2.5,BACK CAB
S7 645 076 1133 SCREW 3X8,HEAT SINK TO IC 301
S8 645 023 6594 SCREW ST 3X8,AUDIO BD
S9 645 023 6594 SCREW ST 3X8,
HEAT SINK TO TOP CAB
S10 645 023 6594 SCREW ST 3X8,ANT JACK
S11 645 062 1116 SCR 3X15,BACK COVER
S12 645 062 1109 SCR 2.6X4,
MOTOR BRACKET TO BACK CAB
S13 645 023 6594 SCREW ST 3X8,
MOTOR BRACKET TO BACK CAB
S14 645 027 1168 SCR 3X8,SCREW CLIP TO SW PCB
S15 645 023 6617 SCREW ST 3X10,
LINE CORD HOLDLE
ELECTRICAL-PARTS
REF.NO. PART NO. DESCRIPTION
12 !
!! 645 081 7915 POWER TRANSFORMER
18 645 076 1478 HEAT SINK,FOR IC 301
20 645 062 1215 CD DOOR MOTOR
645 076 1966 HOUSING 5P,
MAIN CN801,CN802 TO CD M
645 062 0928 2P CONNECTOR,SPEAKER
645 055 7255 16P FFC CABLE,
CD BD CN902 TO CD DECK
645 076 1119 FFC CABLE 10P,
MAIN CN901 TO CD BD CN90
645 076 1904 HOUSING 4P,
MAIN CN304 TO AUDIO CN30
645 081 8004 HOUSING 5P,
MAIN CN403 TO CD BD CN90
645 076 1928 HOUSING 7P,
MAIN CN306 TO AUDIO CN30
645 076 1935 HOUSING 8P,
MAIN CN701 TO CTL CN702
645 076 1942 HOUSING 5P,
MAIN CN301 TO CN302
645 076 1959 HOUSING 4P,
MAIN CN401 TO LED CN404,

- 7 -
PARTS LIST
REF.NO. PART NO. DESCRIPTION
AUDIO P.W.BOARD ASSY
REF.NO. PART NO. DESCRIPTION
70 614 333 2558 ASSY,PWB,AUDIO(Only initial)
CN305 645 062 0959 7P HEADER
CN307 645 027 3803 WAFER 4P
IC301 645 076 1065 IC LA4628
Q0301 645 033 3538 TR 2SD1936S AC
Q0302 645 033 3538 TR 2SD1936S AC
645 076 1478 HEAT SINK,FOR IC 301
645 076 1485 SHIELD PLATE,FOR AUDIO PCB
CD P.W.BOARD ASSY
REF.NO. PART NO. DESCRIPTION
71 614 333 2602 ASSY,PWB,CD(Only initial)
CF901 645 052 4837 RESONATOR 16.934MHZ
CN901 645 076 1102 10P FFC HEADER
CN902 645 055 7163 16P FFC HEADER
CN903 645 054 0660 5P HEADER
IC901 645 076 1423 IC LC78646E
IC902 645 076 1430 IC LC78684E
IC903 645 076 1416 IC LA6548
IC904 645 076 1447 IC M12L16161A
L0906 645 042 0108 CHOKE COIL 26UH
Q0901 645 073 8579 TRANSISTOR 2SA812
Q0902 645 033 3514 TR 2SB764D
Q0903 645 072 3162 TRANSISTOR 9014C
SW901 645 069 6657 LEAF SWITCH
645 070 9050 HEAT SINK,FOR IC903
LED L P.W.BOARD ASSY
REF.NO. PART NO. DESCRIPTION
72 614 333 2572 ASSY,PWB,LED L(Only initial)
LED401 645 076 1089 LED
LED R P.W.BOARD ASSY
REF.NO. PART NO. DESCRIPTION
73 614 333 2589 ASSY,PWB,LED R(Only initial)
LED402 645 076 1089 LED
CD DOOR SWITCH P.W.BOARD ASSY
REF.NO. PART NO. DESCRIPTION
74 614 333 2596 ASSY,PWB,
CD DOOR SWITCH(Only initial)
SW001 645 062 0836 MICRO SW
SW002 645 062 0836 MICRO SW
CONTROL P.W.BOARD ASSY
REF.NO. PART NO. DESCRIPTION
75 614 333 2565 ASSY,PWB,CONTROL(Only initial)
LED701 645 062 0881 LED
LED702 645 062 0881 LED
REM701 645 076 1041 DIODE RPM7100
SW702 645 042 0023 SW TACT,POWER
SW703 645 042 0023 SW TACT,SLEEP
SW704 645 042 0023 SW TACT,MEMORY/CLOCK
SW705 645 042 0023 SW TACT,TUNER/BAND
SW706 645 042 0023 SW TACT,FB/BS
SW707 645 042 0023 SW TACT,FF/FS
SW708 645 042 0023 SW TACT,STOP
SW709 645 042 0023 SW TACT,PLAY/PAUSE
SW710 645 042 0023 SW TACT,AUX
SW711 645 042 0023 SW TACT,SOUND/PRESENT
SW712 645 042 0023 SW TACT,BASS
SW713 645 042 0023 SW TACT,OPEN/CLOSE
MAIN P.W.BOARD ASSY
REF.NO. PART NO. DESCRIPTION
76 614 333 2541 ASSY,PWB,MAIN(Only initial)
AC001 645 027 1298 EYELET
AC002 645 027 1298 EYELET
BF101 645 051 6467 BAND PASS FILTER
C0111 645 073 7992 POLYESTER 0.001U 100V
C0118 645 073 8029 POLYESTER 0.01U 100V
C0119 645 073 8029 POLYESTER 0.01U 100V
C0303 645 073 8043 POLYESTER 0.022U 100V
C0304 645 073 8043 POLYESTER 0.022U 100V
C1105 645 076 1027 CE 6800U 16V
CF101 645 055 6906 CERAMIC FILTER
CF102 645 055 1130 CERAMIC FILTER
CF103 645 055 1130 CERAMIC FILTER
CF104 645 055 6920 CERAMIC FILTER
CN401 645 042 9552 HEADER 4PINS
CN701 645 051 6559 8P HEADER
CN801 645 051 6535 5P HEADER
CN901 645 076 1102 10P FFC HEADER
D0101 645 055 6821 DIODE 1N4148
D0102 645 055 6821 DIODE 1N4148
D0103 645 055 6821 DIODE 1N4148
D0104 645 055 6821 DIODE 1N4148
D0105 645 055 6821 DIODE 1N4148
D0403 645 055 6821 DIODE 1N4148
D0405 645 055 6821 DIODE 1N4148
D0406 645 023 6112 RECTIFIER 1N-4001
D0407 645 023 6112 RECTIFIER 1N-4001
D0408 645 023 6112 RECTIFIER 1N-4001
D0701 645 055 6821 DIODE 1N4148
D0702 645 055 6821 DIODE 1N4148
D0703 645 055 6821 DIODE 1N4148
D0704 645 055 6821 DIODE 1N4148
D0706 645 055 6821 DIODE 1N4148
D0901 645 055 6821 DIODE 1N4148
D0902 645 055 6821 DIODE 1N4148
D1101 645 027 0932 RECTIFIER 1N-5401
D1102 645 027 0932 RECTIFIER 1N-5401
D1103 645 027 0932 RECTIFIER 1N-5401
D1104 645 027 0932 RECTIFIER 1N-5401
D1105 645 023 6112 RECTIFIER 1N-4001
F1101 645 062 0935 GLASS FUSE,FS1101
IC101 645 055 6975 IC LA1823ESIA
IC102 645 055 7019 IC LC72131
IC401 645 066 5790 IC KA7808
IC502 645 055 7026 IC LC75342
IC701 645 076 1454 IC LC877148A-54K14JK05
IC904 645 062 0782 IC LB1641
JK101 645 076 1164 SPEAKER TERMINAL
JK301 645 062 1147 ST PHONEJACK
JK303 645 076 1171 ANTENNA JACK+RCA JACK
L0102 645 062 0812 FM COIL
L0103 645 023 6280 FM COIL
L0104 645 062 0874 CHOKE COIL 39MH
L0105 645 062 0874 CHOKE COIL 39MH
L0107 645 027 0352 CHOKE COIL 100UH
L0108 645 023 6297 VHF COIL
L0301 645 062 0867 CHOKE COIL 10UH 2A
L0302 645 062 0867 CHOKE COIL 10UH 2A
L0303 645 062 0867 CHOKE COIL 10UH 2A
L0304 645 062 0867 CHOKE COIL 10UH 2A
L0402 645 033 3637 CHOKE COIL 10UH
L0601 645 033 3637 CHOKE COIL 10UH
L0602 645 033 3637 CHOKE COIL 10UH
L0603 645 033 3637 CHOKE COIL 10UH
L0701 645 033 3637 CHOKE COIL 10UH
L0702 645 033 3637 CHOKE COIL 10UH
L0801 645 062 0850 FERRITE BEAD
L0802 645 062 0850 FERRITE BEAD
L0803 645 062 0850 FERRITE BEAD
LCD701 645 076 1072 LCD DISPLAY
Q0101 645 027 3797 TR 9018H
Q0102 645 034 7078 TR 2SC3330U
Q0103 645 027 0420 TR 8050C
Q0104 645 055 6876 TR 9018F
Q0105 645 055 6869 TR 8550B C
Q0106 645 023 6129 TR 9014C
Q0403 645 076 1058 TRANSISTOR KSB772Y
Q0404 645 023 6129 TR 9014C
Q0405 645 027 0420 TR 8050C
Q0406 645 023 6129 TR 9014C
Q0407 645 023 6129 TR 9014C
Q0408 645 023 6129 TR 9014C
Q0409 645 023 6129 TR 9014C

- 8 -
PARTS LIST
REF.NO. PART NO. DESCRIPTION
Q0410 645 023 6129 TR 9014C
Q0411 645 055 6883 TR KSA928A
Q0412 645 027 0420 TR 8050C
Q0414 645 023 6129 TR 9014C
Q0701 645 023 6129 TR 9014C
Q0702 645 032 9890 TR KTC-9015C
Q0703 645 032 9890 TR KTC-9015C
Q0704 645 023 6129 TR 9014C
Q0705 645 032 9890 TR KTC-9015C
SW701 645 062 0829 SW TACT,RESET
T0101 645 062 0775 IFT,IFT OSC OA10-871104
T0102 645 033 3866 AM COIL,IFT IF 2070
T0103 645 055 6944 IFT,IFT OSC 1A612R
TC101 645 023 6310 TRIMMER 10PF
TC102 645 023 6310 TRIMMER 10PF
VD101 645 062 0713 DIODE ISV101
VD102 645 062 0713 DIODE ISV101
VD103 645 055 6814 DIODE SVC348
VR701 645 076 1188 POTATY ENCODER,
EC12E224204F20
X0101 645 062 0904 CRYSTAL
X0701 645 055 7125 CRYSTAL
X0702 645 076 1096 CRYSTAL 6MHZ
ZD101 645 055 6838 ZENER 5.6V
ZD102 645 062 0744 ZENER 9.1V
ZD401 645 062 0737 ZENER 6.2V
ZD402 645 055 6838 ZENER 5.6V
ZD702 645 044 6924 ZENER DIODE 3.9V
ZD703 645 073 8135 ZENER 3V
ZD901 645 044 6924 ZENER DIODE 3.9V
645 035 0511 FUSE HOLDER MW1010K,FS1101
645 042 0320 HEAT SINK,36X23X1.2MM

- 9 -
WIRING CONNECTION
This is a basic wiring connection.

- 11 -- 10 -
This is a basic schematic diagram.
SCHEMATIC DIAGRAM (MAIN)

- 13 -- 12 -
SCHEMATIC DIAGRAM (CD )
This is a basic schematic diagram.

- 15 -- 14 -
SCHEMATIC DIAGRAM (MAIN A SIDE )

- 17 -- 16 -
SCHEMATIC DIAGRAM (MAIN B SIDE)

- 19 -- 18 -
WIRING DIAGRAM (AUDIO , CD DOOR SW , CONTROL , LED L & LED R)
AUDIO
CD DOOR SW CONTROL
LED L
LED R

- 21 -- 20 -
WIRING DIAGRAM (CD )
SANYO Electric Co., Ltd.
Osaka, Japan
Sep./ '05 BB Printed in Japan

- 19 -- 18 -
WIRING DIAGRAM (AUDIO , CD DOOR SW , CONTROL , LED L & LED R)
AUDIO
CD DOOR SW CONTROL
LED L
LED R

- 21 -- 20 -
WIRING DIAGRAM (CD )
SANYO Electric Co., Ltd.
Osaka, Japan
Sep./ '05 BB Printed in Japan